Motor vehicle door structure

Abstract

A vehicle door assembly has an inner sheet metal layer ( 16 ) which presents a substantially U-shaped structure. The inner sheet metal layer includes a latch mounting surface and at least one hinge mounting surface. An outer, substantially planar, sheet metal layer ( 14 ) is attached to the inner sheet metal layer to form a cavity. A structural reinforcement member ( 30 ) is disposed in the cavity to reinforce the inner and outer sheet metal layers, including reinforcements ( 44 A, B and 28 A, B) for the latch and hinge mounting surfaces. A carrier assembly ( 60 ) is mounted to the structural reinforcement member, covering the U-shaped area, and a trim component ( 50 ) covers the carrier assembly. By incorporating the structural door member, the thickness of the inner and outer sheet metal layers can be reduced, for a net weight and reduced material cost savings.

1. A structural automotive door body, comprising:
 an inner sheet metal layer, the inner sheet metal layer including a latch mounting surface and at least one hinge mounting surface; 
 an outer sheet metal layer; and 
 a structural reinforcement member disposed between the inner and outer sheet metal layers to reinforce the inner and outer sheet metal layers and providing at least one hinge reinforcement and a latch reinforcement; 
 wherein said inner sheet metal layer includes a pair of spaced apart end walls connected only by a bottom wall extending between said pair of spaced apart end walls thereby defining a substantially U-shaped structure having an open upper portion and said structural reinforcement member includes a top member that abuts said outer sheet metal layer and extends thereacross adjacent said open upper portion of said U-shaped structure of said inner sheet metal layer. 
 
     
     
       2. A structural automotive door body according to  claim 1 , wherein said structural reinforcement member includes a side impact beam. 
     
     
       3. A structural automotive door body according to  claim 2 , wherein said structural reinforcement member includes a bottom cross-member that abuts and supports the inner and outer sheet metal layers. 
     
     
       4. A structural automotive door body according to  claim 3 , wherein said structural reinforcement member is welded to said inner sheet metal layer. 
     
     
       5. A structural automotive door body according to  claim 4 , wherein said outer sheet metal layer is hemmed to said inner sheet metal layer. 
     
     
       6. A structural automotive door body according to  claim 1 , wherein said structural reinforcement member includes a middle cross member, a bottom cross member, and continuous side peripheries, said top member reinforcing said outer panel, said middle cross member extending between said side peripheries to function as a side impact beam, said bottom cross-member abutting and reinforcing said inner and outer sheet metal layers; and wherein said side peripheries include at least one hinge reinforcement and a latch reinforcement. 
     
     
       7. A structural automotive door body, comprising:
 an inner sheet metal layer including a pair of spaced apart end walls connected only by a bottom wall extending between the pair of spaced apart end walls thereby defining a substantially U-shaped structure having an open upper portion; 
 an outer sheet metal layer; 
 at least one of the inner and outer sheet metal layers including a latch mounting surface and at least one hinge mounting surface; 
 a structural reinforcement member disposed between the inner and outer sheet metal layers, said member comprising top, middle and bottom cross-members and contiguous side peripheries, wherein: 
 said top member abuts and extends across said outer sheet metal layer adjacent the open upper portion of said U-shaped structure of said inner sheet metal layer; 
 said middle cross member extends between said side peripheries to function as a side impact beam; 
 said bottom cross-member abuts and supports said inner and outer sheet metal layers; and 
 said side peripheries include at least one hinge reinforcement and a latch reinforcement. 
 
     
     
       8. A door assembly, comprising:
 an inner sheet metal layer defining a substantially U-shaped structure, the inner sheet metal layer including a latch mounting surface and at least one hinge mounting surface; 
 an outer, substantially planar, sheet metal layer; 
 a structural reinforcement member disposed between the inner and outer sheet metal layers for reinforcing the inner and outer sheet metal layers and providing at least one hinge reinforcement and a latch reinforcement; 
 a carrier assembly, including a belt-line loading member connected to a non-structural hardware carrier having at least a window regulator mounted thereon, said carrier assembly being mounted to at least the structural reinforcement member and covering the U-shaped area; and 
 a trim component for covering said carrier assembly. 
 
     
     
       9. A door assembly according to  claim 8 , wherein said hardware carrier includes a secondary trim component which provides a shelf structure for a map pocket and said trim component includes a wall for said map pocket. 
     
     
       10. A door assembly according to  claim 8 , wherein said window regulator includes at least one rail having one end mounted to said belt-line loading member and means for adjusting the lateral and vertical position of the other end of said at least one rail. 
     
     
       11. A structural automotive door body, comprising:
 an inner sheet metal layer, the inner sheet metal layer including a pair of spaced apart end walls connected only by a bottom wall extending between the pair of spaced apart end walls, said inner sheet metal layer also including a latch mounting surface and at least one hinge mounting surface; 
 an outer sheet metal layer; and 
 a structural reinforcement member disposed between the inner and outer sheet metal layers, said structural reinforcement member including top, middle and bottom cross-members and continuous side peripheries, said top member reinforcing said outer panel, said middle cross member extending between said side peripheries to function as a side impact beam, said bottom cross-member abutting and reinforcing said inner and outer sheet metal layers; and wherein said side peripheries include at least one hinge reinforcement and a latch reinforcement.